Electrical distribution system having integral junction box for instrument panel application

Abstract

An assembly for supplying vehicle subsystems associated with an instrument panel. A panel structural architecture includes a forward facing side within which are defined a series of partially recessed and interconnected channels. A junction box is secured or integrally affixed in some fashion to the structural architecture and an electrically communicable network extending from the junction box is likewise secured to surfaces of the panel structural architecture. First selected branches of the network terminate in a plurality of high current connectors extending from first locations. Second selected branches of the network terminate in a plurality of low current connectors extending from further locations. An instrument panel skin is applied over the structural architecture and incorporates electrical subsystems with input connectors matingly engageable with both the high and low current connectors associated with the structural architecture.

What is claimed is:  
     
       1. An electrical distribution assembly for supplying a number of individual vehicle subsystems associated with an instrument panel, said assembly comprising: 
       an instrument panel structural architecture having a specified shape and size;  
       a junction box secured to said panel structural architecture;  
       an electrically communicable network communicating with and extending from said junction box;  
       a first selected branch of said communicable network terminating in at least a first high current connector according to a first structural configuration and extending from a location of said panel structural architecture;  
       a second selected branch of said harness network terminating in at least a second low current connector according to a second structural configuration and extending from a further location of said panel structural architecture; and  
       an instrument panel skin applied over said structural architecture, said panel skin incorporating a first electrical subsystem having at least one additional connector matingly engageable with said high current connector according to said first structural configuration, said panel skin incorporating a second electrical subsystem having a further connector matingly engageable with said low current connector according to said second structural configuration.  
     
     
       2. The electrical distribution assembly as described in  claim 1 , said instrument panel structural architecture further comprising a three dimensional construction with a plurality of configured interior apertures adapted to receive HVAC plenum structure associated with the vehicle. 
     
     
       3. The electrical distribution assembly as described in  claim 1 , further comprising said junction box securing to a rearside and corner location of said instrument panel structural architecture. 
     
     
       4. The electrical distribution assembly as described in  claim 1 , said electrically communicable network further comprising a plurality of wire harnesses. 
     
     
       5. The electrical distribution assembly as described in  claim 1 , said electrically communicable network further comprising a plurality of fiber optic harnesses. 
     
     
       6. The electrical distribution assembly as described in  claim 1 , said electrically communicable network further comprising a plurality of flex circuit harnesses. 
     
     
       7. The electrical distribution assembly as described in  claim 2 , a forward facing side of said three dimensionally constructed instrument panel structural architecture defining a series of partially recessed and interconnected channels for receiving said electrically communicable network. 
     
     
       8. The electrical distribution assembly as described in  claim 1 , said low current connectors further comprising a conductive elastomer material having at least one substantially planar surface, a plurality of raised button portions extending in a given direction from said planar surface and through which current flowing communication is established with said associated electrical subsystem. 
     
     
       9. The electrical distribution assembly as described in  claim 8 , said low current connectors each further comprising a specified shape and size, said first electrical subsystem further comprising a plurality of subsystems including at least one of a clock, radio, GPS tracking system, HVAC control settings, passenger compartment lamp, and steering column controls. 
     
     
       10. The electrical distribution assembly as described in  claim 1 , said high current connectors further comprising a terminal having a specified shape and size, said second electrical subsystem further comprising a plurality of subsystems including at least one of a instrument panel cluster display, window winding mechanism, and air bag triggering mechanism. 
     
     
       11. An electrical distribution assembly for supplying a number of individual vehicle subsystems associated with an instrument panel, said assembly comprising: 
       an instrument panel structural architecture having a three dimensional construction with a specified shape and size, a forward facing side of said panel structure architecture further comprising a series of partially recessed and interconnected channels;  
       a junction box secured to said panel structural architecture;  
       an electrically communicable network communicating with and extending from said junction box, said network being receivingly engaged within said recessed and interconnected channels;  
       first selected branches of said harness network terminating in a plurality of high current connectors according to a first structural configuration and extending from a first plurality of locations of said panel structural architecture;  
       second selected branches of said harness network terminating in a plurality of low current connectors according to a second structural configuration and extending from a further plurality of locations of said panel structural architecture; and  
       an instrument panel skin applied over said structural architecture, said panel skin incorporating a first plurality of electrical subsystems having connectors matingly engageable with said high current connectors, said panel skin incorporating a second plurality of electrical subsystems having further connectors matingly engageable with said low current connectors.